Method and apparatus for forming envelope blanks from a web

ABSTRACT

A plurality of rolls of web material are positioned on tandem supports in spaced relation to a die unit having a horizontally reciprocable punch. The webs are unwound from the rolls with the webs in overlying relation and are fed to a web feeder unit positioned above the die unit. The web feeder unit feeds the plurality of webs in overlying relation along a generally vertical path into the die unit where the webs are momentarily stopped as the movable punch cuts envelope blanks from the web. The envelope blanks are ejected from the die unit into a receiver unit positioned in substantially the same plane as the die unit where the formed envelope blanks are stacked. The remaining portions of the webs are discharged through a discharge device positioned below the die unit.

Elite States Patent [1 1 Oggoian [451 Apr. 9, 1974 METHOD AND APPARATUS FOR FORMING [73] Assignee: F. L. Smithe Machine Company,

Inc., Ducansville, Pa.

[22] Filed: Feb. 22, 1972 [21] Appl. No.: 227,851

[52] US. Cl 83/96, 83/27, 83/50, 83/140, 83/236, 83/911, 93/61 R [51] Int. Cl B3lb 1/16 [58] Field of Search 93/61 R; 83/911, 23, 27, 83/29, 50, 55, 86, 96, 104, 236, 259, 261, 650, 136, 140

[56] References Cited UNITED STATES PATENTS 2,307,889 l/l943 Korsgaard 83/50 1,913,119 6/1933 .loachimczyk 83/911 X 2,372,008 3/1945 Krueger 93/61 R 3,461,760 8/1969 White 83/96 X 3,523,474 8/1970 Kinslow, Jr. et a1. 83/50 X 2,391,304 12/1945 Fink ..83/136X Primary ExaminerRoy Lake Assistant Examiner-James F. Coan Attorney, Agent, or Firm-Stanley J. Price, Jr.

[5 7 ABSTRACT A plurality of rolls of web material are positioned on tandem supports in spaced relation to a die unit having a horizontally reciprocable punch. The webs are unwound from the rolls with the webs in overlying relation and are fed to a web feeder unit positioned above the die unit. The web feeder unit feeds the plurality of webs in overlying relation along a generally vertical path into the die unit where the webs are momentarily stopped as the movable punch cuts envelope blanks from the web. The envelope blanks are ejected from the die unit into a receiver unit positioned in substantially the same plane as the die unit where the formed envelope blanks are stacked. The remaining portions of the webs are discharged through a discharge device positioned below the die unit.

5 Claims, 3 Drawing Figures PATENTEU APR 9 I974 SHEET 1 BF 2 METHOD AND APPARATUS FOR FORMING ENVELOPE BLANKS FROM A WEB CROSS-REFERENCE TO RELATED APPLICATIONS Copending applications entitled, Die Cutter Drive For An Envelope Blank Forming Machine and Apparatus For Forming Printed Envelope Blanks From Web Material filed under even date herewith and assigned to the assignee of the present invention disclose other features of the apparatus for forming envelope blanks from a web.

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a method and apparatus for forming envelope blanks from web material and more particularly to a method and apparatus for forming envelope blanks from web material fed vertically into a horizontally reciprocable die unit.

2. Description of the Prior Art Presently there are two known methods for forming envelope blanks. One method, as is illustrated in U.S. Pat. Nos. 3,129,622; 2,718,260 and 3,370,492 includesa multi-position die that cuts a plurality of envelope blanks from a stack of paper sheets. This method for making envelope blanks from a stack of large sheets of paper is limited in the number of blanks that can be formed within a predetermined period of time and substantial handling of the severed blanks is required to remove the blanks from the die and stack the blanks for use in an envelope machine.

It is also known to form generally diamond shaped envelope blanks from a continuous web by severing the web along a diagonal by a plurality of severing devices, as is illustrated in U.S. Pat. Nos. 2,951,408 and 3,143,938. This type of apparatus for forming envelope blanks is limited specifically to the conventional diamond shaped envelope blank and cannot be modified to form envelope blanks for booklet, pocket or banker type envelopes.

U.S. Pat. No. 3,01 1,377 discloses apparatus for forming envelope blanks for booklet or banker type envelopes from a web including apparatus to first sever the web longitudinally and then cut notches in the side of the web to form the side flaps of the envelope blank. Rotating cutter devices sever the notched webs to form envelope blanks that are thereafter stacked in a receiver device. The apparatus illustrated in U.S. Pat. No. 3,01 1,377 is limited to the particular configuration of envelope blanks illustrated therein. To change either the length of width of the envelope blank or the envelope blank side flap configuration requires substantial dismantling and modification of the blank forming apparatus. There is need for a method and apparatus to rapidly and continuously form envelope blanks of preselected configurations from web material and apparatus that can be quickly converted from one envelope blank configuration to another.

SUMMARY OF THE INVENTION In accordance with the present invention there is provided a method and apparatus for forming envelope blanks from a web which includes a support device for the web material that is operable to rotatably support rolls of web material and permit unwinding of the web from the rolls. A die unit having a reciprocable punch is arranged to cut envelope blanks from the web material and is positioned in spaced relation to the support device. The reciprocable punch is positioned to reciprocate in a substantially horizontal plane. A web feed device unwinds the web material from the rolls and intermittently feeds the web material into the die unit. The web feed device is positioned above the die unit so that the web material follows a generally vertical path from the feed device into the die unit. A drive is provided to reciprocate the punch in timed relation'to the feed of the web material. A receiver for the envelope blank formed from the web material has an end portion on the same plane as the die unit and is arranged to receive and stack the' envelope blank formed from the web material. A discharge means is positioned below the die unit to receive the remaining portion of the web material after the envelope blanks are cut therefrom.

With the above apparatus it is now possible to form envelope blanks of various configurations from web material by feeding the web material into a die unit having a punch and die of the desired envelope blank configuration. The envelope blanks formed in the die unit are transferred to a receiver where the envelope blanks are stacked.

Accordingly, the principal object of this invention is to provide a method and apparatus for forming envelope blanks of different configurations from web material.

Another object of this invention is to provide a method and apparatus for forming envelope blanks from web material and simultaneously stacking the formed envelope blanks in a horizontal receiver. These and other objects of this invention will be more completely described and disclosed in the following specification, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view in side elevation of the envelope blank forming apparatus.

FIG. 2 is a fragmentary view taken along the line lIIl of FIG. 1, illustrating the feed apparatus for the web material.

FIG. 3 is a fragmentary view in side elevation taken along the line Ill-III in FIG. 2, illustrating a portion of the feed apparatus.

I DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings there is illustrated a blank forming apparatus generally designated by the numeral 10 that includes a web unwind unit 12, a feed unit 14 and a die cutting unit 16. The unwind unit 12 includes a plurality of supports 18 for rolls of web material 20. The support units 18 are arranged in tandem relation so that the web 22 from roll 20 is positioned in overlying relation with the web 24 from the other roll 20 as the webs are fed to the feeder unit 14. Although only two rolls of web material are illustrated, it should be understood that a greater number of rolls may be so positioned and the web material therefrom is fed in overlying stacked relation to the feed unit 14.

The supports 18 have upwardly extending posts 26 and 28 with idler rolls or cylinders 30 and 32 rotatably mounted thereon at substantially the same elevation. The webs 22 and 24 extend around the respective idler cylinders 30 and 32 and are fed over a web guide unit 34 on post 36 extending upwardly from the frame 38 of the envelope blank forming apparatus 10. Printing units 40 and 42 extend rearwardly from the post 36 and where a single roll of web material is employed, the web may be fed through the printing units prior to being fed to the feeder unit 14.

The blank forming apparatus frame 38 has a substantially horizontal platform or base portion 44 on which a die support 46 is secured adjacent the front end. The die support 46 has a base secured to the platform 44 and an upwardly extending wall 48 and a horizontal top wall 50. The wall 48 has a suitable receiver for a die plate and a suitable opening to permit the passage of envelope blanks therethrough.

The feeder unit 14 has a pair of side frames 52 and 54 secured to the die support top wall 50 and extend upwardly therefrom. A pair of feed cylinders 56 and 58 are rotatably mounted in the frame members 52 and 54 adjacent the upper portion thereof. The feed cylinder 58 is mounted in slots in the side frames 52 and 54 and is arranged to be urged against the cylinder 56. A web guide 60 extends rearwardly from the frame members 52 and S4 and is arranged to guide the webs 22 and 24 around the cylinder 56 and then between cylinders 56 and 58 as indicated in dotted lines in FIGS, 1 and 3 and as illustrated in FIG. 2. An adjustable intermittent feed cylinder 62 is rotatably mounted in the frame members 52 and 54 below the feed cylinders 56 and 58.

A drive motor 64 is positioned beneath the blank forming apparatus platform 44 and has a suitable speed reducer 66 connected thereto. A drive pulley 68 is connected to the output shaft of reducer 66 and is arranged to rotate in the direction indicated in FIG. 1. A drive pulley 70 is rotatably connected to a shaft 72 journaled in the frame members 52 and 54 of feeder unit 14. The shaft 72 has a gear 74 mounted thereon for rotation therewith. The gear 74 meshes with a gear 76 connected to the shaft, 78 of feed cylinder 56. A resilient type pressure device 80 is arranged to urge cylinder 58 against cylinder 56 so that rotation of cylinder 56 by gear 76 will frictionally engage and exert a tension on the webs 22 and 24 laced around cylinder 56 and between cylinders 56 and 58 and unwind the webs from the respective rolls 20. The webs are fed downwardly by the cylinders 56 and 58 onto the rear surface of a guide plate 82 into frictional engagement with a pressure cylinder 84. The intermittent feed cylinder 62 extends through an elongated slot 86 in the plate 82 into engagement with the web material 22. The pressure cylinder 84 is urged toward the intermittent feed cylinder 62 by an adjustable pressure control device 90. The pressure cylinder 84 with the pressure control device 90 is pivotally mounted on flanges 92 that extend rearwardly from feeder unit side frames 52 and 54 in a manner that spring 94 urge the cylinder 84 toward the intermittent feed cylinder 62 to frictionally engage the webs therebetween.

As is illustrated in FIGS. 2 and 3, the shaft 72 journaled in the feeder unit side frames 52 and 54 has a hub portion 96 mounted thereon on the outboard side of the frame 54. The hub 96 has a radially extending slot 98 therein in which the end portion 100 of arm 102 is mounted. The other end 104 of arm 102 is secured in a hub 106 on shaft 108. The shaft 108 is joumaled in the frame members 52 and 54 and has the intermittent feed cylinder 62 mounted thereon so that the intermittent feed cylinder 62 rotates with the shaft 108. The end portion 104 of arm 102 is axially displaced on hub member 106. With this arrangement, the rotation of shaft 72 is transmitted through the arm member 102 through shaft 108 to intermittent feed cylinder 62. The displacement of the connection between the end portions and 104 of arm 102 on the respective hub members 96 and 106 provides intermittent rotation for cylinder 62 and the intermittent downward feed of the webs 22 and 24. A suitable adjustment screw 112 is provided to radially adjust the arm end portion 100 in slot 98 to regulate and control the intermittent feed of the .webs 22 and 24.

The die cutting unit 16 includes a rear die plate and a front die plate 122. The front die plate 122 is secured to the upwardly extending wall 48 of the die support 46 and has a suitable opening with a configuration similar to the envelope blank configuration desired. The front die plate 122 has four rearwardly extending tubular supports, two of which are illustrated in FIG. 1 and designated 124 and 126. The rear die plate 120 has mating guide posts designated 128 and 130 that extend into the tubular supports 124 and 126 so that the rear die plate 120 is supported from the front die plate 122. A stripper plate 132 is mounted on four other posts 134 extending forwardly from rear die plate 120. The stripper plate 132 is yieldingly supported on the posts 134 and is arranged to clamp the webs against a mating plate on the rear die plate 120 as the cutter die or punch 136 is mounted on rear die plate 120 is moved into cutting relation with the webs 22 and 24. The punch 136 is arranged to eject the envelope blanks cut from the web material through opening in front die plate assembly into a receiver 110 positioned in front of the front die plate 122.

A suitable drive mechanism 138 is arranged to reciprocate the rear die plate 120 and is diagrammatically illustrated. Any suitable reciprocating device that translates rotary motion into reciprocatory motion, such as a reciprocating lever device, may be employed as the drive mechanism. The reciprocating portion of the drive mechanism has a connector 142 extending forwardly therefrom. The connector 142 is secured in a yoke 144 extending rearwardly from the rear die plate 120 by a pin so that reciprocation of the connector 142 is transmitted through yoke 144 to the rear die plate 120. A drive pully 146 is secured to the drive mechanism shaft and is drivingly connected to the drive pulley 68 by a drive belt 148. A second drive pulley (not shown) is coaxially mounted on shaft 140 and has a drive belt 150 reeved therearound and around pulley 70 connected to shaft 72. With this arrangement, drive from motor 64 is transmitted to the drive mechanism 138 and also transmitted to the web feeder unit 14 so that the web material is fed in timed relation to the reciprocation of the die plate 120.

The receiver 110 for the envelope blank includes a base portion 152 and side support arm 154. The end portion of the receiver adjacent the die plate 122 is positioned on substantially the same plane as the opening in plate 122 so that the cut out envelope blanks ejected by the punch 136 through opening in die plate 122 are discharged through the opening in die plate 122 into the receiver 152 where the envelope blanks are supported in a generally vertical position as illustrated in FIG. 1. A suitable discharge chute 156 is formed between the front portion of frame 38 and is arranged to receive the remaining portion of the web material after the envelope blanks have been cut therefrom. A suitable tension control 160 may be provided on the unwind unit to control the tension on the web as the feeder unit 14 unwinds the webs 22 and 24 from the rolls and 22.

As above described, it is now possible to form envelope blanks of various configurations rapidly from web material and to provide a plurality of webs in overlying stacked relation for the die cutting operation. Further, it is now possible to quickly change the configuration of the envelope blanks by removing the die plates and punch in the die cutting unit 16 and replacing them with a die plate and a punch of a different envelope configuration. The web material is fed generally vertically to the die unit and the envelope blanks are ejected horizontally into a receiver where they are stacked.

Although the above apparatus has been described in conjunction with the forming of envelope blanks from web material, it should be understood that the invention is not limited thereto and apparatus similar to that above described may be employed with other types of strip material to cut preselected shaped blanks therefrom.

According to the provisions of the patent statutes, I have explained the principle, preferred construction and mode of operation of my invention and have illustrated and described what I now consider to represent its best embodiment. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.

l claim:

1. Apparatus for forming blanks from web material comprising,

reciprocable die means operable to cut blanks of a preselected configuration from web material, said die means having a portion arranged to reciprocate in a substantially horizontal plane,

said reciprocable die means including a first stationary die plate and a second reciprocable die plate,

said first stationary die plate having an aperture therein with a configuration of the blank cut from the web material,

said second reciprocable die plate having a punch member extending therefrom, said punch member having a configuration substantially the same as the blank cut from the web material, said punch member positioned in overlying relation with said aperture in said first stationary die plate,

telescopic support means connecting said second reciprocable die plate to said stationary die plate, said telescopic support means arranged to support said second reciprocable die plate on said stationary die plate as said second reciprocable die plate moves toward and away from said first stationary die plate,

a stripper plate mounted on said second reciprocable die plate and arranged to engage said web material fed into said die means and stop the feed of said web material while said punch on said reciprocable die plate cuts a blank therefrom.

feed means including feed rolls and feed cylinders arranged to continuously rotate at varying velocities to intermittently feed said web material into said die means,

said feed means positioned above said die means so that said web material follows a generally vertical path from said feed means into said die means,

drive means to reciprocate a portion of said die means in timed relation to said feed means and drive said feed means,

receiver means for the blanks formed from said web material, said receiver means having an end portion positioned in the same plane as said die means, said receiver means arranged to receive and stack said blanks formed from said web material, and

discharge means positioned below said'die means to receive the remaining portions of said web material after said blanks are cut therefrom.

2. Apparatus for forming blanks from web material as set forth in claim 1 which includes,

paper web material fed to said die means by said feed means, and

said die means arranged to cut envelope blanks of different configurations from said paper web material.

3. Apparatus for forming blanks from web material as set forth in claim 1 in which said feed means includes,

a first feed cylinder mounted above said die means, said drive means operable to rotate said first feed cylinder at a relatively constant velocity,

a second feed cylinder mounted adjacent to said first feed cylinder and operable to frictionally engage said web material to said first feed cylinder so that web material extending around said first feed cylinder and between said first and second feed cylinders is fed downwardly from said feed means to said die means,

an intermittent third feed cylinder mounted below said first feed cylinder,

a fourth pressure cylinder mounted adjacent to said intermediate third feed cylinder, said fourth pressure cylinder arranged to frictionally engage the web material to said intermittent third feed cylinder, and

means connecting said drive means to said third intermittent feed cylinder so that said third intermittent feed cylinder rotates at a non-uniform velocity and feeds the web material downwardly into said die means at a non-uniform velocity.

4. Apparatus for forming blanks from web material as set forth in claim 1 which includes,

means to support a plurality of rolls of web material in tandem relation to each other and spaced from said feed means,

said support means operable to rotatably support said rolls of web material to permit unwinding of the web material from said rolls,

means to maintain the plurality of webs from said rolls of web material in overlying relation and simultaneously unwinding said plurality of webs from said rolls of web material,

means to feed the plurality of webs in overlying relation to said feed means, and

said feed means arranged to feed said plurality of webs to said die means so that a plurality of blanks are cut during each stroke of said reciprocable portion of said die means.

5. Apparatus for forming blanks from web material v as set forth in claim 4 in which,

a plurality of webs of paper material are fed by said feed means to said die means in a generally vertical direction, and

rial. 

1. Apparatus for forming blanks from web material comprising, reciprocable die means operable to cut blanks of a preselected configuration from web material, said die means having a portion arranged to reciprocate in a substantially horizontal plane, said reciprocable die means including a first stationary die plate and a second reciprocable die plate, said first stationary die plate having an aperture therein with a configuration of the blank cut from the web material, said second reciprocable die plate having a punch member extending therefrom, said punch member having a configuration substantially the same as the blank cut from the web material, said punch member positioned in overlying relation with said aperture in said first stationary die plate, telescopic support means connecting said second reciprocable die plate to said stationary die plate, said telescopic support means arranged to support said second reciprocable die plate on said stationary die plate as said second reciprocable die plate moves toward and away from said first stationary die plate, a stripper plate mounted on said second reciprocable die plate and arranged to engage said web material fed into said die means and stop the feed of said web material while said punch on said reciprocable die plate cuts a blank therefrom, feed means including feed rolls and feed cylinders arranged to continuously rotate at varying velocities to intermittently feed said web material into said die means, said feed means positioned above said die means so that said web material follows a generally vertical path from said feed means into said die means, drive means to reciprocate a portion of said die means in timed relation to said feed means and drive said feed means, receiver means for the blanks formed from said web material, said receiver means having an end portion positioned in the same plane as said die means, said receiver means arranged to receive and stack said blanks formed from said web material, and discharge means positioned below said die means to receive the remaining portions of said web material after said blanks are cut therefrom.
 2. Apparatus for forming blanks from web material as set forth in claim 1 which includes, paper web material fed to said die means by said feed means, and said die means arranged to cut envelope blanks of different configurations from said paper web material.
 3. Apparatus for forming blanks from web material as set forth in claim 1 in which said feed means includes, a first feed cylinder mounted above said die means, said drive means operable to rotate said first feed cylinder at a relatively constant velocity, a second feed cylinder mounted adjacent to said first feed cylinder and operable to frictionally engage said web material to said first feed cylinder so that web material extending around said first feed cylinder and between said first and second feed cylinders is fed downwardly from said feed means to said die means, an intermittent third feed cylinder mounted below said first feed cylinder, a fourth pressure cylinder mounted adjacent to said intermediate third feed cylinder, said fourth pressure cylinder arranged to frictionally engage the web material to said intermittent third feed cylinder, and means connecting said drive means to said third intermittent feed cylinder so that said third intermittent feed cyLinder rotates at a non-uniform velocity and feeds the web material downwardly into said die means at a non-uniform velocity.
 4. Apparatus for forming blanks from web material as set forth in claim 1 which includes, means to support a plurality of rolls of web material in tandem relation to each other and spaced from said feed means, said support means operable to rotatably support said rolls of web material to permit unwinding of the web material from said rolls, means to maintain the plurality of webs from said rolls of web material in overlying relation and simultaneously unwinding said plurality of webs from said rolls of web material, means to feed the plurality of webs in overlying relation to said feed means, and said feed means arranged to feed said plurality of webs to said die means so that a plurality of blanks are cut during each stroke of said reciprocable portion of said die means.
 5. Apparatus for forming blanks from web material as set forth in claim 4 in which, a plurality of webs of paper material are fed by said feed means to said die means in a generally vertical direction, and said die means arranged to cut a plurality of envelope blanks from said plurality of webs of paper material. 